WO2012142194A2 - Lame de coupe composite - Google Patents

Lame de coupe composite Download PDF

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Publication number
WO2012142194A2
WO2012142194A2 PCT/US2012/033167 US2012033167W WO2012142194A2 WO 2012142194 A2 WO2012142194 A2 WO 2012142194A2 US 2012033167 W US2012033167 W US 2012033167W WO 2012142194 A2 WO2012142194 A2 WO 2012142194A2
Authority
WO
WIPO (PCT)
Prior art keywords
cutting
segment
hub
blade
composite blade
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2012/033167
Other languages
English (en)
Other versions
WO2012142194A3 (fr
Inventor
Adam R. LOUKUS
Josh E. LOUKUS
David M. SOMERO
Niel S. SOMERO
Nathan K. SOMERO
David W. SOMERO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
REL Inc
Original Assignee
REL Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by REL Inc filed Critical REL Inc
Publication of WO2012142194A2 publication Critical patent/WO2012142194A2/fr
Priority to US13/793,305 priority Critical patent/US20130269498A1/en
Publication of WO2012142194A3 publication Critical patent/WO2012142194A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28D—WORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
    • B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
    • B28D1/12—Saw-blades or saw-discs specially adapted for working stone
    • B28D1/121—Circular saw blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D61/00—Tools for sawing machines or sawing devices; Clamping devices for these tools
    • B23D61/02—Circular saw blades
    • B23D61/028—Circular saw blades of special material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D65/00—Making tools for sawing machines or sawing devices for use in cutting any kind of material

Definitions

  • This disclosure generally relates to cutting and/or grinding devices and blades used for cutting and/or grinding, and more particularly relates to cutting blades having a composite structure.
  • a diamond blade generally includes a circular steel disc with a diamond bearing edge.
  • the diamond bearing edge is often formed from a mixture of diamonds and metal powders which are pressed and sintered to form a solid metal alloy in which the diamonds are suspended.
  • the diamond bearing edge (or portions thereof) are usually securely attached to the steel core with a mechanism such as brazing or laser welding.
  • a composite blade includes one or more cutting segments extending along a periphery of a hub segment.
  • the hub segment includes one or more recesses adjacent its periphery, wherein each one of the one or more recesses is configured for receiving at least a portion of at least one of the one or more cutting segments.
  • the hub segment and each one of the one or more cutting segments received within at least one of the one or more recesses are metallurgically bonded.
  • Each one of the one or more cutting segments may include a cutting material and a first porous material, and the hub segment may include a second porous material which is different from or the same as the first porous material.
  • a molten metal infiltrates the voids (or pores) of both the first and the second porous material, and creates a metallurgical bond between at least portions of the first and the second porous material, i.e., between at least portions of the hub segment and the one or more cutting segments received within the one or more recesses of the hub segment.
  • a composite blade includes one or more cutting segments along a periphery of a hub segment.
  • the hub segment includes a first porous material that is at least partially infiltrated by a metal.
  • the hub segment and each one of the one or more cutting segments are metallurgically bonded.
  • each one of the one or more cutting segments includes a cutting material and a second porous material that is at least partially infiltrated by the metal.
  • the second porous material may be the same as or different from the first porous material.
  • the metallurgical bond is formed at least partially by the metal within both the hub segment and each one of the one or more cutting segments.
  • a method of manufacturing a composite blade includes several steps, some of which may be performed in parallel while others may be performed sequentially.
  • the manufacturing starts with providing one or more cutting segment preforms, each at least partially defining a cutting segment of the composite blade.
  • Each one of the one or more cutting segment preforms include a cutting material and a first porous material.
  • a hub preform, which at least partially defines a hub segment of the composite blade is also provided.
  • the hub preform includes a second porous material and one or more recesses adjacent its periphery. Each recess in the hub preform is configured for receiving at least a portion of each one of the one or more cutting segment preforms.
  • a blade preform is assembled by positioning at least a portion of each one of the one or more cutting segment preforms within at least one of the one or more recesses in the hub preform.
  • the blade preform is positioned within a die cavity and molten metal is introduced into the die cavity.
  • the molten metal at least partially infiltrates both the hub preform and each one of the one or more cutting segment preforms, and creates a metallurgical bond between at least a portion of the hub segment and at least the portion of each one of the one or more cutting segments received within the one or more recesses in the hub preform.
  • the cutting segment preforms include a first porous material and a cutting material (e.g., diamond particles).
  • the hub preform and thus also the hub segment, includes a second porous material and a reinforcing material (e.g., ceramic fibers and/or particles).
  • one or both of the first and the second porous material are a ceramic material.
  • the first porous material and/or the second porous material are a ceramic material including silicon carbide.
  • the first porous material in the cutting segment preform has a volume fraction between approximately 40% by volume and approximately 65% by volume.
  • the second porous material in the hub segment preform has a volume fraction between approximately 10% by volume and approximately 50% by volume.
  • each one of the one or more cutting segments includes at least one cutting edge and/or cutting surface which are/is at least partially defined by the cutting material.
  • the composite blade is configured for removing heat away from the cutting edge and dispensing it at a rate substantially faster than prior art cutting blades. In some cases, this can provide a composite blade with an extended life cycle.
  • the hub segment and each cutting segment are fixedly attached to one another by the metallurgical bond which eliminates or reduces separation during operation. In certain cases, an infiltrated metal enhances the structural integrity, including the strength and stiffness, of the composite blade.
  • the composite blade in some embodiments of the invention, operates at a decreased noise level relative to prior art cutting blades.
  • FIG. 1A is a perspective view of a composite blade in accordance with an embodiment
  • FIG. IB is a partial cross-sectional view along line A-A of the composite blade of FIG. 1A;
  • FIG. 2 is a flow chart illustrating a method of manufacturing a composite blade in accordance with some embodiments
  • FIG. 3A is a perspective view of a partially assembled blade preform in accordance with an embodiment
  • FIG. 3B is a partial cross-sectional view of the hub preform of FIG. 3 A taken along line B-B in FIG. 3A;
  • FIG. 3C is a perspective view of a fully assembled blade preform in accordance with an embodiment
  • FIG. 3D is a partial cross-sectional view along line C-C of the fully assembled blade preform of FIG. 3C;
  • FIG. 3E is a perspective view of a portion of the fully assembled blade preform of FIG. 3C;
  • FIG. 4A is a perspective cross-sectional view of a blade preform positioned within a disassembled die cavity before introduction of a molten metal in accordance with some embodiments;
  • FIG. 4B is a perspective cross-sectional view of the blade preform of FIG. 4A encased in the metal and being removed from the die cavity in accordance with an embodiment
  • FIG. 5A is a perspective cross-sectional view of a blade preform illustrating a final blade design to be machined in accordance with some embodiments.
  • FIG. 5B is a cross-sectional view of the blade preform of FIG. 5 A.
  • FIG. 1A is a perspective view of composite blade 10 in accordance with some embodiments
  • FIG. IB is a partial cross-sectional view along line A-A of composite blade 10 shown in FIG. 1A.
  • Composite blade 10 includes hub segment 12 with mounting hole 14, and one or more cutting segments 16 along periphery (e.g., edge or perimeter) 18.
  • periphery e.g., edge or perimeter
  • the cutting segments 16 are distributed in a a circular configuration about the circular perimeter of the hub segment, though other arrangements may be possible for other geometries.
  • adjacent segments of one or more cutting segments 16 are separated from one another by one or more recesses 20 such that the cutting segments are distributed along periphery 18 in a spaced-apart, clocked relationship.
  • one or more cutting segments 16 are generally referred to in the art as "teeth" of a cutting blade.
  • one or more recesses 20 extend radially a short distance from periphery 18 towards mounting hole 14 at the center of composite blade 10. While one or more recesses 20 are shown as being linear and extending through one or more cutting segments 16 and into at least a portion of hub segment 12, this does not always have to be the case.
  • one or more recesses 20 may be shaped as a curve. In some cases one or more recesses 20 may not extend into hub segment 12 or may extend a shorter or longer distance into hub segment 12.
  • cutting segments 16 may be tightly distributed about the periphery without recesses 20.
  • the recesses or other features may instead be machined into the final product.
  • a waterjet machining process is described further herein may be used to achieve the desired configuration for the cutting segments 16.
  • composite blade 10 is a metal matrix composite blade having two or more segments metallurgically bonded to one another.
  • composite blade 10 includes two metallurgically bonded segments including hub segment 12 and one or more cutting segments 16 along periphery 18.
  • hub segment 12 adjacent periphery 22 of the hub segment, hub segment 12 includes one or more recesses 24 extending into at least a portion of hub segment 12.
  • One or more recesses 24 are configured for receiving at least a portion of one or more cutting segments 16.
  • the recesses may be configured as slots extending along the periphery or perimeter of the hub segment.
  • embodiments are not limited to one particular form of recess for receiving a portion or all of a cutting segment.
  • a metal e.g., a metal element, compound, or metal alloy
  • the metallurgical bond is formed along at least a portion of interface 26 between hub segment 12 and each cutting segment 16.
  • FIG. 2 illustrates a method of manufacturing a composite blade such composite blade 10 in accordance with some embodiments. The method is described herein below with reference to FIGS. 3A-5B which illustrate composite blade 10 at a few exemplary stages during manufacture.
  • a method of manufacturing composite blade 10 starts at block 50 by providing one or more cutting segment preforms 52 and by providing hub preform 54 at block 56.
  • each one of one or more cutting segment preforms 52 include a cutting material and a first porous material
  • hub preform 54 includes a second porous material and a reinforcing material.
  • the cutting material includes diamonds.
  • the reinforcing material includes fibers (e.g., ceramic fibers) and/or particles.
  • the first and the second porous materials are the same porous material or substantially similar porous materials that are hard, stiff and highly resistive to wear.
  • porous material examples include reinforced ceramic, ceramic material such as silicon carbide (SiC), carbon graphite, ceramic and/or non-ceramic fibers or particles, foam, or any combination thereof.
  • the porosity and/or the density of the first and the second porous material i.e., of one or more cutting segment preforms 52 and of hub preform 54, can be individually manipulated.
  • both the first and the second porous material while composed of different substances, may yet have the same or substantially similar volume fractions and/or densities.
  • the first porous material in the cutting segment preform has a volume fraction between approximately 40% by volume and approximately 65% by volume.
  • the second porous material in the hub preform has a volume fraction between approximately 10% by volume and approximately 50% by volume.
  • hub preform 54 includes at least one or more recesses 24 configured for receiving at least a portion of one or more cutting segment preforms 52. Accordingly, blade preform 62 is formed at block 64 by positioning one or more cutting segment preforms 52 within one or more recesses 24 of hub preform 54. It will be appreciated that one or more recesses 24 can be of different depth and width in different embodiments. For example, in some
  • one or more recesses 24 have opposing walls of substantially equal lengths and are therefore configured for housing one or more cutting segment preforms 52 in their entirety.
  • opposing walls 58 and 60 of one or more recesses 24 are of different lengths.
  • one or more cutting segment preforms 52 are somewhat spaced apart at locations 66 when positioned within one or more recesses 24. In some cases, though, the one or more cutting segment preforms 52 abut one another when positioned within one or more recesses 24.
  • blade preform 62 is optionally preheated at step 68 before positioning it in die cavity 70 of die 72 at block 74, and introducing molten metal into die cavity 70, i.e., casting, at block 76.
  • blade preform 62 is preheated in an inert environment.
  • preheating blade preform 62 enhances the distribution of the molten metal within the first and the second porous materials of one or more cutting segment preforms 52 and hub preform 54, respectively.
  • preheating blade preform 62 increases the likelihood that the molten metal is distributed efficiently and consistently within the pores of the first and the second porous materials of one or more cutting segment preforms 52 and hub preform 54, respectively.
  • the combining the cutting segment preform inserts with the hub preform provides enhanced thermal properties for the cutting segments.
  • combining the smaller cutting segments with the larger hub segment increases the overall thermal mass of the blade preform, which enhances heat storage within both the hub preform and the cutting segment performs. Accordingly, in many cases after heating 68 the blade preform, heat will not leave the cutting segments as quickly as it might leave stand-along or separate cutting segments as used in past designs.
  • die 72 includes first section 78, second section 80 and plunger 82 configured for extending through and for travel within shot sleeve 84 of first section 78.
  • Die cavity 70 is at least partially defined by opposing surfaces of first and second sections 78 and 80 when positioned against one another.
  • blade preform 62 is positioned in die cavity 70 and sandwiched between first and second sections 78 and 80, respectively.
  • Plunger 82 is retracted away from die cavity 70 (and blade preform 62) and molten metal is introduced into die cavity 70.
  • pressure is applied to the molten metal within die cavity 70 by pushing plunger 82 into die 72 towards blade preform 62 within die cavity 70.
  • the molten metal penetrates through the surfaces of one or more cutting segment preforms 52 and hub preform 54, and is forced into the voids (or pores) of the first and the second porous materials.
  • the metal cools and solidifies, it forms a metallurgical bond between hub preform 54 and the cutting segment preforms 52 within the recesses 24 of hub preform 54.
  • Cast 86 when first removed from die 72, includes metal impregnated blade preform 62 encased in an outer shell of metal.
  • FIGS. 5A and 5B respectively illustrate perspective and side cross-sectional views of cast 86 encased in metal 94 and superimposed with silhouette 92 of composite blade 10.
  • metal impregnated blade preform 62 can be removed to form the final product composite blade 10 as at least partially defined by silhouette 92.
  • the removal of at least some portions of metal impregnated blade preform 62 may include removing at least a portion of the first and/or the second porous material.
  • portions of the performs or porous materials may be removed in order to form the final casting into the desired predefined shape and/or in accordance with predetermined blade dimensions and specifications. According to some embodiments, making the final casting thicker (e.g., with extra metal 94 around the blade preform 62) provides flexibility for tailoring the hub geometry.
  • the casting may be machined to add a cooling fin or tailor the amount of heat sink material for directing heat away from the blade to a rotor core.
  • metal impregnated blade preform 62 may be removed for providing one or more radially extending recesses 20 along periphery 18.
  • At least a portion of the cutting material in one or more cutting segments 16 may be exposed along periphery 18 by removing at least some portions of the first and/or the second porous material.
  • one or more waterjets may be used for machining purposes.
  • a waterjet e.g., a high pressure stream of water and abrasive
  • the waterjetting process allows for the segment sizes to be altered, allowing minimization of segment degradation with less undercutting, and precise control of blade balance.
  • the recesses between the segments can be optimized to avoid trapping debris in areas where it can cause wear.
  • the use of a waterjet in the final cutting allows for the segment sizes to be much larger.
  • the cutting segments machined by waterjetting can mimic the sizes seen in a typical finished blade.
  • embodiments may not be constrained to the usual sizes for cutting segments, but can instead be made much longer to minimize handling and preform assembly issues of the segments into the hub.
  • a blade preform may only need six diamond preforms in order to fully encircle the hub preform.
  • waterjetting may also or instead be used to expose the cutting material (e.g., diamond) in the cutting segments.
  • an erosion technique can be used to expose the cutting material.
  • the use of a waterjet is a tool that can work well for erosion techniques in some situations.
  • aluminum and SiC particles that coat and cover diamond cutting material after the casting process need to be taken away to allow the blade to cut efficiently.
  • a waterjet contains an abrasive that can remove such cutting material.
  • Garnet is a typical abrasive used in commercial waterjetting and can be an effective, cost effective abrasive that can be utilized to abrade the aluminum and SiC particles away.
  • a waterjet can also use SiC, alumina, etc. as abrasives, but the are typically more expensive and require very hard coated nozzles on the waterjet.
  • a waterjet used to machine the final casting is a CNC (Computer Numerical Control) controlled unit that can follow a specified pattern to direct a stream of water and abrasive at a location for a set period of time. Using this method can in some cases optimize the amount of exposure of the diamonds in a cutting segment.
  • CNC Computer Numerical Control
  • the metal filling the voids of the first and the second porous material enhances the physical properties of composite blade 10.
  • the metal is a pure metallic substance of a single composition or a metal alloy.
  • a metal (e.g., element, compound, or alloy) having a relatively higher thermal conductivity can in some cases increase the thermal conductivity of the hub segment of composite blade 10, which can increase the rate of heat transfer from the cutting segments 16 toward a center 14 of hub segment 12 where it is further dissipated. Accordingly, in some cases the cutting segments 16 may be relatively cooler during operation that in past designs and therefore less prone to wear, and the warping propensity of composite blade 10 will be reduced.
  • composite blade 10 will inherit at least a portion of the structural properties generally associated with metals, such as stiffness, hardness, strength, damping capacity, etc. Accordingly, composite blade 10 can be made stronger and stiffer than non-composite blades.
  • hub preform 54 comprises silicon carbide, alumina, and silica, which when infiltrated by a metal, provides a higher combined thermal conductivity than the thermal conductivity associated with hub components of past blade designs.
  • hub preform 54 is formed from a 40% SiC - 2 % Saffil RF milled fiber (95% Alumina- 5% Silica) and infiltrated with an aluminum alloy and/or magnesium molten metal mixture.
  • the cast stiffness for such an example can be
  • the ultimate strength is 45-48 Ksi.
  • thermal conductivity of SiC can range from 140 W/m-K (e.g., Washington Mills Carborex RA black SiC) to 440 W/m-K (e.g., electrical grade green pure SiC).
  • the thermal conductivity of aluminum alloy can range from 109 W/m-K (e.g., A319- T6) to 222 W/m-K (e.g., 1100-O) commercially pure aluminum.
  • the thermal conductivity of magnesium AZ91D is about 72.76 W/m-K.
  • thermal conductivity K p parallel to the axis of a fiber embedded in a matrix can be estimated according to the following equation:
  • K K f V f + (l-V V,) K
  • K f the thermal conductivity of the fiber
  • V f the fiber volume fraction
  • K m the thermal conductivity of the fiber.
  • the hub segment includes a hub preform including silicon carbide that is infiltrated by aluminum provide a low estimate for thermal conductivity of 121 W/m-K and a high estimate for thermal conductivity of 309 W/m-K.
  • a typical stainless steel hub included in past saw blade designs can have a thermal conductivity closer to about 20 W/m-K. Accordingly, the effective thermal conductivity of the hub segment (e.g., as determined by the rule of mixtures) in these examples of the composite blade can provide a significantly higher thermal conductivity, thus enabling heat to be more quickly transferred away from the cutting segments of the composite blade.
  • the cutting segment can have an estimated thermal conductivity of between 615 W/m-K and 746 W/m-K depending upon the grade of silicon carbide and aluminum used. Comparing these values to the extremely low thermal conductivity for stainless steel (20 W/m-k) can provide some insight into the difficulties that prior blade designs incorporating stainless steel hubs have effectively removing heat generated by the cutting segments. In contrast, the depicted embodiments illustrated in Tables 1 and 2 show how a metal matrix composite hub segment can provide a thermal conductivity much closer to the conductivity of the cutting segments, thus providing more effective heat transfer away from the cutting segments.
  • thermal conductivity of composite blade 10 can be affected, it will be apparent to one skilled in the art that additional, or alternative, thermal characteristics can also be easily manipulated.
  • the overall thermal capacity (or thermal mass) of composite blade 10 can be manipulated to provide a desired thermal performance by manipulating the type and/or the quantity of the metal impregnating the hub segment and/or the one or more cutting segments.
  • an increase in the thermal capacity of one or more segments (hub and/or cutting) will further enhance the distribution and/or consistency of the metal impregnating the one or more segments of composite blade 10.
  • composite blade 10 is illustrated and described generally as a circular blade, this should not be considered as a limitation of the disclosed invention.
  • the geometrical configuration of a composite blade could be in the form of a cylindrical coring bit or a grinding wheel.
  • the techniques can be applied to long rope saws that are used to cut marble from quarries.
  • an advantage of the composite blade structure described herein with respect to some embodiments is that all of the components of the blade (e.g., the hub segment and all cutting segments) are cast into one integrated structure in a single shot.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mining & Mineral Resources (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

Selon l'invention, dans certains cas, une lame de coupe composite comprend un ou plusieurs segments de coupe le long de la périphérie d'un segment de moyeu. Selon un exemple, le segment de moyeu et le ou les segments de coupe peuvent comprendre le même matériau poreux ou des matériaux poreux différents. Une liaison métallurgique entre le ou les segments de coupe et le segment de moyeu est créée par un métal qui infiltre le matériau poreux des deux segments. Le ou les segments de coupe comprennent également un matériau de coupe qui définit au moins partiellement un bord de coupe et/ou une surface de coupe de chaque segment de coupe s'étendant le long de la périphérie de la lame composite.
PCT/US2012/033167 2011-04-11 2012-04-11 Lame de coupe composite Ceased WO2012142194A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US13/793,305 US20130269498A1 (en) 2012-04-11 2013-03-11 Composite Cutting Blade

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161516931P 2011-04-11 2011-04-11
US61/516,931 2011-04-11

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US13/793,305 Continuation US20130269498A1 (en) 2012-04-11 2013-03-11 Composite Cutting Blade

Publications (2)

Publication Number Publication Date
WO2012142194A2 true WO2012142194A2 (fr) 2012-10-18
WO2012142194A3 WO2012142194A3 (fr) 2013-03-14

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Application Number Title Priority Date Filing Date
PCT/US2012/033167 Ceased WO2012142194A2 (fr) 2011-04-11 2012-04-11 Lame de coupe composite

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Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5471970A (en) * 1994-03-16 1995-12-05 Diamant Boart, Inc. Method of manufacturing a segmented diamond blade
US7017465B2 (en) * 2002-07-29 2006-03-28 L.S. Starrett Company Cutting tool with grooved cutting edge
KR100839518B1 (ko) * 2007-01-26 2008-06-19 신한다이아몬드공업 주식회사 다이아몬드 공구 및 그 제조방법
DE102008015845B3 (de) * 2008-03-27 2009-11-19 Böhler-Uddeholm Precision Strip GmbH & Co. KG Bimetallband zur Herstellung von Sägeblättern, Sägebändern oder Streichrakeln

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Publication number Publication date
WO2012142194A3 (fr) 2013-03-14

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